BACKGROUND OF THE INVENTION1. Field of the Invention[0001]
The present invention relates to a water and weather proof textile fabric and, more particularly to such a textile fabric that is suitable for use to make luggage, bags, and shoes.[0002]
2. Description of the Related Art[0003]
For the advantages of light weight and comfort touch, textile fabric is intensively used to make luggage, sports bags, backpacks, and shoes. The structural strength of a textile fabric is determined subject to the quality of the base fabric material, the diameter of the threads, the thread count, and the weaving method. Well control of these factors makes the textile fabric strong enough, preventing an excessive extension under a load. Conventionally, a piece of textile product is made by directly cutting a cloth of fabric subject to a predetermined pattern and then making the cut piece of fabric into the finished product by stitching. A textile product made according to this method is not highly acceptable to consumers because it cannot protect the user against water and strong wind. In order to improve this drawback, a back coating layer may be coated on the back side of the fabric, i.e., to form a thin layer of polymeric substance on the fabric, or to coat the fabric with a layer of synthetic material. The back coating layer protects against water, reinforces the strength of the fabric, and gives a comfort touch. If to make the product elastic (calenderable), the polymeric coating must be elastic, i.e., stretchable. This kind of polymeric coating can be prepared from a polymeric material of monomer type. Normally, copolymers of different types of monomers are synthesized to provide the desired properties. Further, softener may be added to enhance the softness and flexibility of the polymeric material.[0004]
Among polymers, the following materials are commonly used for making the aforesaid back coating layer: PVC (polyvinyl chloride) and its copolymers, polyacrylate and its copolymers, PA (polyamide), synthetic rubber and its copolymers, and silicon rubber. During evaporation of solvent in the system, polymeric material dissolved or dispersed in organic solvent forms a continuous film of polymers. Alternatively, the polymeric material can be applied to the fabric as water dispersion element. When water evaporated from dispersion element, a continuous polymeric film is formed on the fabric. If thermoplastic polymer is used, it can be applied to the fabric when melted.[0005]
According to conventional technology, PVC is commonly used for making a back coating on a fabric. However; because PVC generates dioxin and other toxic gasses when burnt, it is harmful to the environment and human beings. Therefore, the use of PVC to make a back coating on a fabric is gradually prohibited. Further, PVC material is relatively heavy, not suitable for making luggage, bags, and shoes of light weight.[0006]
PE (polyethylene), EVA (ethylene-vinyl-acetate copolymer), or the mixture of PE and EVA may be used for making a back coating for fabric. However, these materials have the properties of plastics, i.e., the drawbacks of high hardness and rigidity. A fabric coated with a back coating of one of these materials is less flexible, and tends to wrinkle. Therefore, the aforesaid materials are not commonly used fabric materials for making luggage, bags, and shoes.[0007]
Therefore, it is desirable to provide a textile fabric of low pollutant, high softness and elasticity, and good waterproof property.[0008]
SUMMARY OF THE INVENTIONThe present invention has been accomplished under the circumstances in view. It is therefore the main object of the present invention to provide a textile fabric, which is soft, elastic, and water proof, and practical for use to make luggage, bags, and shoes.[0009]
According to the present invention, the textile fabric comprises a fabric base layer and a back coating layer. The fabric base layer is made from nylon or polyester, having a front side and a back side. The back coating layer has a bonding side bonded to the back side of the fabric base layer, and a back body side. The back coating layer is prepared from TPU (thermoplastic polyurethane), PS (polystyrene), EVA (ethylene vinyl acetate), processing oil, plastics, and additives subject to a predetermined formula.[0010]
A bonding layer may be selectively used and bonded between the fabric base layer and the back coating layer. The bonding layer has a first side bonded to the back side of the fabric base layer, and a second side bonded to the bonding side of the back coating layer. Preferably, the bonding layer is prepared from PMMA (polymethyl methacrylate), viscosity index improver, additives, and toluene.[0011]
Comparing to conventional methods, the invention uses TPU (thermoplastic polyurethane), PS (polystyrene) and EVA (ethylene vinyl acetate) to substitute for polyvinyl chloride, reducing possible pollution to environment. Further, the back coating layer prepared from the aforesaid materials is soft and elastic, not easy to wrinkle, and more particularly, water proof. When using the textile fabric to make luggage, bags, shoes, etc., either the fabric base layer or the back coating layer can be exposed to the outside.[0012]
Thereafter, prepare a[0023]back coating material405 containing TPU, PS, EVA (100PHR), processing oil (0˜120PHR), plastics (0˜100PHR), and additives (0˜20PHR). The preparedback coating material405 is mixed by a screw and then melted (melting index over 3 g/min), and then rolled by a set ofhot rollers406 into a sheet ofback coating407 at temperature within about 90˜160° C., as shown in FIG. 3B, and then the sheet ofback coating407 and thebonding agent403coated fabric401, which is preheated, are bonded together through a set ofimpression rollers408, and then the textile fabric thus obtained is delivered through a set of coolingrollers409 and cooled down. The surface of the back coating layer, i.e. theback coating407, is embossed when it passes through the impression rollers.